How to Convert Gerber to DXF: Complete Guide for PCB and Mechanical Integration

Modern product design rarely stays in one discipline. Your PCB layout needs to fit inside an enclosure, align with mounting holes, interface with connectors, and work alongside mechanical components. The problem? PCB designers speak Gerber while mechanical engineers speak DXF. If you’ve ever needed to share your board outline with a mechanical designer or prepare files for CNC routing, you know the challenge. This guide covers everything you need to know about how to convert Gerber to DXF, including the best tools, step-by-step methods, and tips for getting clean, usable results.

Why Convert Gerber to DXF?

Before jumping into the conversion process, let’s understand why this conversion matters. Gerber files are the standard for PCB manufacturing, containing precise vector data about copper layers, solder masks, silkscreen, and board outlines. But they exist in a specialized format that most mechanical CAD tools can’t read directly.

DXF (Drawing Exchange Format), developed by Autodesk, is the universal language of mechanical CAD. Nearly every CAD program, from AutoCAD to SolidWorks to Fusion 360, can import DXF files. Converting Gerber to DXF opens up a world of possibilities for cross-disciplinary collaboration.

Use Case	Why DXF Is Needed
Enclosure design	Import board outline to verify fit and clearances
Mechanical integration	Check connector positions and mounting holes
CNC routing/milling	Many CNC machines read DXF directly
Laser cutting	Create fixtures, stencils, or enclosure cutouts
Assembly documentation	Generate accurate mechanical drawings
3D modeling	Import PCB shape into SolidWorks or Fusion 360
Panel design	Create manufacturing panels with routing paths

Benefits of Converting Gerber to DXF

Benefit	Description
Universal compatibility	DXF works with virtually all CAD software
Editable geometry	Modify outlines, add features, adjust dimensions
Mechanical collaboration	Share data with MCAD engineers directly
Manufacturing flexibility	CNC, laser, and water jet machines accept DXF
Archival value	Long-term storage in widely-supported format
Documentation	Create accurate technical drawings and specs

Understanding Gerber and DXF Formats

To convert Gerber to DXF effectively, it helps to understand what makes these formats similar and where they differ.

Gerber Format Overview

Gerber files use vector commands to describe PCB features. The format is essentially a series of instructions: move to this coordinate, draw a line with this aperture, flash a pad here. Modern RS-274X (Extended Gerber) files embed aperture definitions, making them self-contained.

Gerber Characteristic	Description
Data type	Vector-based ASCII commands
Primary use	PCB manufacturing
Geometry	Traces, pads, polygons, arcs
Coordinate system	Cartesian X-Y with configurable units
Layer structure	One file per layer typically
Apertures	Shape definitions for draws and flashes

DXF Format Overview

DXF also uses vector graphics, which is why Gerber-to-DXF conversion works well conceptually. However, DXF supports a much broader range of entity types designed for general mechanical drafting.

DXF Characteristic	Description
Data type	ASCII or binary vector format
Primary use	Mechanical CAD interchange
Entity types	Lines, polylines, circles, arcs, text, blocks
Layer support	Multiple layers in single file
Line widths	Supported via LWPOLYLINE entities
3D capability	Can contain 3D data (though 2D more common for PCB)

Key Conversion Considerations

When converting from Gerber to DXF, several translation decisions must be made:

Gerber Element	DXF Translation Options
Traces with width	Polylines with width, or outlined boundaries
Round pads	Circles or filled polygons
Complex apertures	Converted to polyline outlines
Arcs	Arc entities or approximated polylines
Filled regions	Hatched areas or boundary polylines
Text	Often lost or converted to geometry

Methods to Convert Gerber to DXF

Several approaches exist for converting Gerber files to DXF format, from professional CAM software to free open-source tools.

Method 1: Using GerbView (Commercial with Trial)

GerbView by Software Companions is one of the most capable tools for Gerber-to-DXF conversion. It handles RS-274D, RS-274X, and Gerber X2 formats and offers extensive output options.

Step-by-Step Process:

1. Download and install GerbView (30-day free trial available)
2. Launch GerbView and go to File → Add Layer
3. Select the Gerber files you want to convert
4. Load any Excellon drill files separately if needed
5. Verify alignment and scale using the Measure tool
6. Go to File → Export → DXF
7. Configure output settings:
   1. File Units (Inch or Metric)
   1. Line Width handling
   1. Arc conversion options
   1. Pad representation (circles vs. polylines)
8. Click Export to generate the DXF file

GerbView DXF Export Settings:

Setting	Options	Recommendation
File Units	Inch / Metric	Match your CAD software preference
Use Line Widths	Yes / No	Yes for accurate trace representation
Replace Arcs with LWPOLYLINE	Yes / No	Yes if target CAD has arc issues
Output round Pads as Circles	Yes / No	Yes for cleaner mechanical drawings
Layer mapping	Per file / Combined	Per file for complex designs

Method 2: Using ViewMate Pro (Commercial)

ViewMate Pro by PentaLogix includes robust DXF export capabilities alongside its Gerber viewing and editing features.

Step-by-Step Process:

1. Download ViewMate Pro from pentalogix.com
2. Import your Gerber files via File → Import → Gerber
3. Import drill files via File → Import → Drill & Route
4. Arrange layers and set visibility as needed
5. Go to File → Export → DXF
6. Configure export parameters
7. Save the DXF file

ViewMate Pro handles complex apertures well and provides control over how Gerber elements translate to DXF entities.

Method 3: Using GBR2DXF from Artwork (Specialized Tool)

GBR2DXF by Artwork Conversion is a dedicated Gerber-to-DXF translator designed specifically for this conversion task.

Key Features:

Feature	Description
Outline conversion	Convert traces to polyline outlines
Layer mapping	Each Gerber file becomes an AutoCAD layer
RS-274D support	Works with legacy Gerber formats
RS-274X support	Full Extended Gerber support
Batch processing	Convert multiple files at once

Step-by-Step Process:

1. Install GBR2DXF from artwork.com
2. Load your Gerber file(s)
3. Configure aperture handling if using RS-274D
4. Select output options:
   1. Polylines with width
   1. Outlined boundaries
   1. Circle representation
5. Export to DXF

This tool is particularly useful when you need outlines rather than filled geometry, which is common for CNC routing applications.

Method 4: Using FlatCAM (Free/Open Source)

FlatCAM is an open-source tool primarily designed for CNC PCB milling, but it can also export to DXF format.

Step-by-Step Process:

1. Download FlatCAM from flatcam.org
2. Open your Gerber file via File → Open Gerber
3. Import drill files via File → Open Excellon
4. Perform any necessary geometry operations
5. Go to File → Export → DXF
6. Save the file

FlatCAM works well for board outlines and simple conversions but may have limitations with complex copper pours.

Method 5: Using CAM350 (Professional)

CAM350 by DownStream Technologies is professional-grade CAM software widely used in PCB manufacturing. Its DXF export is highly configurable.

Step-by-Step Process:

1. Import Gerber files into CAM350
2. Import drill data
3. Verify layer setup and alignment
4. Go to File → Export → DXF/DWG
5. Configure export settings
6. Generate the DXF file

Method 6: Using Altium Designer (If Available)

If you have access to Altium Designer, you can use its CAMtastic module to convert Gerber to DXF.

Step-by-Step Process:

1. Open CAMtastic in Altium Designer
2. Import Gerber files
3. Go to File → Export → DXF
4. Configure settings and export

This method is convenient if you’re already working in the Altium ecosystem.

Method 7: Using reaConverter (Batch Processing)

reaConverter offers batch conversion capabilities for converting multiple Gerber files to DXF.

reaConverter Feature	Description
Batch processing	Convert hundreds of files at once
Format support	GBR, GBS, CMP, SOL, and other Gerber variants
Output options	DXF, DWG, PDF, PNG, and more
Command line	Automation via command-line interface
Watermarking	Add identification marks (optional)

Converting Specific Gerber Layers to DXF

Different Gerber layers serve different purposes when converted to DXF. Here’s guidance on which layers to convert for common use cases:

For Enclosure Design

Gerber Layer	DXF Purpose
Board outline (Edge.Cuts)	Primary enclosure cavity shape
Drill file	Mounting hole locations and sizes
Component outline	Clearance verification for tallest parts
Keepout zones	Areas requiring mechanical clearance

For CNC Routing

Gerber Layer	DXF Purpose
Board outline	Routing path definition
Copper layers	Isolation milling geometry
Drill file	Drilling operations
V-score or tab locations	Panel separation lines

For Mechanical Drawings

Gerber Layer	DXF Purpose
Board outline	Overall dimensions
Silkscreen	Component identification
Assembly drawing	Reference for placement
Drill file	Hole specification callouts

DXF Output Options Explained

When converting Gerber to DXF, several output options affect how the data appears in your CAD software.

Line Width Handling

Option	Result	Best For
Preserve line widths	Polylines with width attribute	Accurate trace representation
Convert to outlines	Closed polylines around trace boundaries	CNC routing paths
Zero-width lines	Centerlines only	Schematic-style drawings

Entity Type Selection

Gerber Element	DXF Entity Options
Circular pads	CIRCLE or LWPOLYLINE
Rectangular pads	LWPOLYLINE (closed)
Traces	LWPOLYLINE with width
Arcs	ARC or approximated LWPOLYLINE
Filled regions	HATCH or boundary LWPOLYLINE

Layer Organization

Most conversion tools offer options for organizing DXF layers:

Organization Method	Description
One layer per Gerber file	Each Gerber becomes a DXF layer
Combined layers	All geometry on single DXF layer
By aperture	Different apertures on different layers
By entity type	Pads, traces, text on separate layers

Best Practices for Gerber to DXF Conversion

After years of converting Gerber files to DXF for various projects, I’ve developed practices that consistently produce good results.

Verify Units Before Conversion

The most common conversion problem is unit mismatch. Always verify:

Check Point	Action
Source Gerber units	Check file header for MO (mode) command
Target DXF units	Match your CAD software preference
Scale verification	Measure known dimensions after conversion

Simplify When Possible

Large copper pours create massive DXF files. For mechanical integration, you typically only need:

• Board outline
• Mounting holes
• Connector cutouts
• Height-restricted zones

Preserve Critical Geometry

Geometry Type	Importance
Board outline	Critical – defines enclosure cavity
Mounting holes	Critical – mechanical fastening points
Connector openings	Important – enclosure cutouts
Component heights	Important for clearance checking
Copper areas	Usually unnecessary for mechanical work

Document Your Conversion Settings

Keep records of:

• Conversion software and version
• Settings used
• Source Gerber file names and dates
• Any post-processing applied

Troubleshooting Common Conversion Issues

Problem: DXF File Shows Wrong Scale

Symptoms: Board appears 25.4x too large or too small

Cause: Inch/millimeter unit mismatch

Solution:

• Check source Gerber units (look for %MOIN*% or %MOMM*%)
• Set conversion tool to matching units
• Verify with known dimensions

Problem: Traces Appear as Thin Lines

Symptoms: All traces are zero-width centerlines

Cause: Line width option disabled or not supported

Solution:

• Enable “Use Line Widths” or equivalent option
• Use “Convert to Outlines” for boundary representation
• Check target CAD software supports LWPOLYLINE widths

Problem: Circles Appear as Polygons

Symptoms: Round pads are multi-sided shapes

Cause: Aperture approximation settings

Solution:

• Enable “Output round Pads as Circles” option
• Increase polygon approximation resolution
• Some precision loss may be acceptable

Problem: Arcs Missing or Distorted

Symptoms: Curved elements don’t display correctly

Cause: Arc entity compatibility issues

Solution:

• Enable arc-to-polyline conversion option
• Check target CAD arc support
• Increase polyline approximation points

Problem: File Size Extremely Large

Symptoms: DXF file is hundreds of megabytes

Cause: Complex copper pours converted to detailed geometry

Solution:

• Convert only necessary layers (outline, drill)
• Use outline mode instead of filled regions
• Simplify complex polygons before export

Resources and Download Links

Commercial Software

Tool	Website	Trial Available
GerbView	gerbview.com	Yes (30 days)
ViewMate Pro	pentalogix.com	Demo available
GBR2DXF	artwork.com	Evaluation
CAM350	downstreamtech.com	Contact vendor
FAB 3000	numericalinnovations.com	Demo available
reaConverter	reaconverter.com	Limited free

Free/Open Source Software

Tool	Website	Platform
FlatCAM	flatcam.org	Windows, Linux, macOS
KiCad GerbView	kicad.org	Windows, Linux, macOS
Gerbv	gerbv.github.io	Windows, Linux, macOS

Online Resources

Resource	URL	Description
Ucamco Gerber Spec	ucamco.com	Official Gerber specification
DXF Reference	autodesk.com	Official DXF documentation
Artwork FAQ	artwork.com/acad/faq	Conversion troubleshooting
Bay Area Circuits Guide	bayareacircuits.com	DXF/Gerber conversion guide

Frequently Asked Questions

Can I convert DXF back to Gerber?

Yes, but it requires careful attention to DXF entity types. Tools like EasyGerb, FAB 3000, and ACE 3000 can convert DXF to Gerber. For best results, use only simple entity types (polylines, circles, text) in your DXF and follow proper design guidelines for filled regions.

Which Gerber layer should I convert for enclosure design?

For enclosure design, convert the board outline layer (typically named Edge.Cuts, Board Outline, or similar) and the drill file. These give you the board shape and mounting hole locations, which are the primary concerns for mechanical fit.

Is the converted DXF suitable for CNC routing?

It depends on the conversion options used. For CNC routing, you typically want outline data (not filled regions) and may need to add tool compensation. Some tools like GBR2DXF and GBRUnion are specifically designed to produce CNC-ready output with proper tool offset considerations.

Will I lose any data converting Gerber to DXF?

Some Gerber-specific information may not transfer directly to DXF, including aperture definitions, net names (in X2/X3 files), and layer function metadata. However, all geometric data should convert accurately. The visual representation in DXF should match the original Gerber when viewed with appropriate settings.

What’s the best free tool for Gerber to DXF conversion?

FlatCAM offers the most complete free solution for basic Gerber to DXF conversion, especially if you’re also interested in CNC milling. For viewing and simple export, the combination of Gerbv for viewing and manual tracing in a CAD program works but is more labor-intensive. For professional results with complex files, commercial tools like GerbView typically produce better output.

Conclusion

Converting Gerber to DXF bridges the gap between PCB design and mechanical engineering. Whether you’re designing an enclosure, preparing files for CNC routing, or creating assembly documentation, the ability to move PCB data into mechanical CAD tools is invaluable.

The key to successful conversion is choosing the right tool for your specific needs and understanding the translation options. For professional work, tools like GerbView and ViewMate Pro offer the most control and best results. For hobbyist projects or occasional conversions, FlatCAM provides capable free functionality.

Remember to verify units, simplify geometry when appropriate, and always check the converted output against known dimensions before committing to manufacturing. With the right approach, Gerber-to-DXF conversion becomes a reliable step in your cross-disciplinary workflow, enabling seamless collaboration between PCB and mechanical design teams.